Canada - Drivetrain- Transfer Case Not Shifting

Bulletin
TSB3015

Issue Date
June 3, 2008

Market
Canada

Title
Transfer Case Not Shifting with Temperatures Below Freezing

Component
DRIVELINE

Models
'07 - '08 Tundra


INTRODUCTION:

Some customers may be concerned about the inability to shift the transfer case between 4WD High, and 4WD Low after an overnight cold soak with temperatures below freezing. An improved transfer case actuator and revised 4WD computer logic has been implemented for this condition. Use the following repair procedure to address this phenomenon.






APPLICABLE VEHICLES:






PRODUCTION CHANGE INFORMATION:






WARRANTY INFORMATION:






PARTS INFORMATION:






REQUIRED SSTS:

NOTE:
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.







REPAIR PROCEDURE:

1. Confirm customer complaint of no shifting between 4WD High, and 4WD Low gear positions after an overnight cold soak with temperatures below freezing (32°F/0°C)

HINT
- If the vehicle is parked inside with temperatures above freezing, normal operation should be observed.
- If the vehicle is driven for 5 - 10 minutes, normal operation may be observed because of transfer case gear oil temperature increasing above 32°F (0°C).

2. Remove the transfer case from the vehicle.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Tundra
- Year: 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Drivetrain
- Keyword: Transfer/4wd/Awd - "JF1A Transfer: Transfer Assembly: Removal

HINT
JF1A transfer case is used on both the 4.7 L and 5.7 L.







3. Remove the 4WD computer from the vehicle.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Tundra
- Year: 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Drivetrain
- Keyword: Transfer/4wd/Awd - "JF1A Transfer: 4WD Control ECU: Removal

4. Install the NEW 4WD computer.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Tundra
- Year: 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Drivetrain
- Keyword: Transfer/4wd/Awd - "JF1A Transfer: 4WD Control ECU: Installation

5. Disassemble the transfer case to replace the transfer case actuator assembly.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Tundra
- Year: 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Drivetrain
- Keyword: Transfer/4wd/Awd - "JF1A Transfer: Transfer Assembly: Disassembly

NOTE
Complete steps 1 through the "Remove Transfer Shift Actuator Assembly" step. Do NOT complete any further steps.

6. Install the NEW transfer case actuator assembly into the transfer case.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Tundra
- Year: 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Drivetrain
- Keyword: Transfer/4wd/Awd - "JF1A Transfer: Transfer Assembly: Reassembly

NOTE
Start at the "Install Transfer Shift Actuator Assembly" step and complete all remaining steps through the end of the Reassembly procedure.

7. Install the transfer case assembly into the vehicle.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Tundra
- Year: 2007 or 2008
- Service Category: Engine/Hybrid System
- Section: Drivetrain
- Keyword: Transfer/4wd/Awd - "JF1A Transfer: Transfer Assembly: Installation

8. Test drive the vehicle and confirm proper operation of the 4WD system.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.